innovation fieldlab zephyros - blauwe cluster · 2020. 9. 18. · innovation fieldlab zephyros....
TRANSCRIPT
Towards Zero downtime andZero on-site maintenance
The partners
Innovation Fieldlab Zephyros
AIRTuB Problem definition
Blade damage (leading edge and structural) leads to:
• (Manual) inspections
• Vessel movements
• Aerodynamic losses, lower AEP
• Expensive repairs
• Reduced up-time
Solution:
Automated inspection and early repairResident drone and crawler
Roadmap of AIRTuB program
AIRTuB 1 ( ongoing, Sept 2019 - Dec 2022)
Automated blade inspection with drone/crawler
Automated damage classification
Relation LE erosion vs. annual energy production (AEP)
Asset management strategy
Robotized LE coating (lab-prototype)
AIRTuB 2 (submitted August 2020)
Robotized Leading Edge repair
Drone residency at turbine (docking station)
Aerodynamic performance of LE repairs
Development of repair recipes
Certification of repairs
AIRTuB 3 ( to be developed)
Advanced prototyping
Optimization
Miniaturization
Demonstration
….?
Commercial application
Levelised cost of energy (LCOE) impact
• Avoiding vessel movements and on-site man-power:• Inspections and repair by rope access is costly• Availability of man-power gets more critical given the anticipated
scale-up in WPP’s• Avoiding vessel movements is extremely cost- and emission effective• Estimated effect: -2% reduction in OPEX
• Less downtime: • Inspection and repair by resident robots is faster • Avoids weather windows (with a resident drone)• Expected to lead to an increase in AEP of 0,1%
• Higher AEP due to less blade erosion:• More frequent inspections and repairs reduces grade of damage• Estimated increase in production of 2%
3D structured light scan
• Goal:• Solid foundation for business cases of drone/crawler inspection.
• Design criteria sensors - the minimum size of damages to be detected.• Sensor development:
• 3 D camera; laser line scanner• Utrasound, terahertz technology
• Blade damage classification:• State of the art wind turbine rotor blade design?• Relation design philosophy wind turbine rotor blades & inspection/maintenance/repair?• Damages in field; locations and sizes?• Damage effect on wind turbine operation?• Erosion/roughness measurement on wind turbine rotor blades?• Impact erosion/roughness on aerodynamic performance?• Blade erosion affecting structural blade properties?
Sensor package development Workpackage 1
© Royal NLR 2020 – All rights reserved
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Ultrasonic inspection
Reference preparation
Thermography
Drone & Crawler Development Workpackage 2 & 3
• Goal:• Drone and Crawler development
• Bringing sensor packages to the blade• 3D visual inspection or laser line scan• Structural damage inspection (crawler!)
• Developments:• Existing drone adaptation
• Reliability, robustness, • Safety; a.o. parachute & floating device
• Flight controller for wind gusts• Path planning: lidar sensor
• Keeping track of leading edge/turbine blade• Crawler development for structural damage inspection sensor• Test & demonstration indoor/outdoor; onshore & offshore demo
Artist impression pictures courtesy of NLR©
Artist impression pictures courtesy of NLR©
Data analysis development Workpackage 4
• Goal:
• Learning from data
• Impact damage on Annual Energy Production
• Cost: operation & maintenance
• Steps:
• Acquisition
• Cleaning
• Enrichment
• Data storage (no live streaming)
• Data Sources:
• Historical Performance data
• Operations
• Maintenance
Repair Technology development Workpackage 5
• Goal:
• Renewal of Leading Edge Protection
• Automated alternative for manual repair
• Parallel development:
• Lab demo of repair technology
• Development will start soon
• Process steps:
• Pretreatment necessary?
• Printing
• Curing
• Wind tunnel testing:
• Effect of protection on aerodynamic efficiency
Erosion Modeling & Repair StrategiesWorkpackage 6
• Goal:• Estimate loss Annual Energy Production (AEP) related to
erosion
• Decision tool for repair strategy
• Aerodynamic modelling of erosion:• Validation against existing and new wind tunnel
measurements
Source Sandia
Business model development Workpackage 7
• Goal:
• New Asset Management Strategy
• business models
• Business Goals and baseline definition:
• Current cost level
• Development of new Strategy scenarios:
• Comparison analysis
• Benefits, Investment, Risk analysis for 2 scenarios compared with the baseline
• Report of overall results
AM Objectives
Performance
Energyconsumption
Maintenance costs
Reliability Strategic action
Option 1 Working in shifts (OPEX)
Option 2 “Base Operation & Maintenance”
Baseline Modification study
AIRTuB programmeDutch innovators are welcome to join!